Method of manufacturing a composite golf club head

ABSTRACT

A method for manufacturing a golf club head with a face component composed of a plurality of plies of pre-preg material and having a striking plate portion with a thickness in the range of 0.010 to 0.250 inches is disclosed herein. The golf club also has a crown component composed of a plurality of plies of pre-preg material and a sole component composed of a plurality of plies of pre-preg material. The golf club head is manufactured using a bladder compression molding process.

CROSS REFERENCES TO RELATED APPLICATIONS

This application is a continuation-in-part application of co-pendingU.S. patent application Ser. No. 09/877,652, filed on Jun. 8, 2001, nowU.S. Pat. No. 6,440,008, which is a continuation of U.S. patentapplication Ser. No. 09/474,670, filed on Dec. 29, 1999, now U.S. Pat.No. 6,248,025, which is continuation-in-part application of U.S. patentapplication Ser. No. 08/958,723, filed on Oct. 23, 1997, now U.S. Pat.No. 6,010,411.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a manufacturing method for a golf clubhead composed of plies of pre-preg sheets. More specifically, thepresent invention relates to a bladder-mold manufacturing method for agolf club head composed of plies of pre-preg sheets.

2. Description of the Related Art

One of the first (if not the first) disclosures of a golf club headcomposed of a plurality of plies of a pre-preg material is Great BritainPatent Application Number 1201648 which was filed in 1967 on behalf ofWilliam Charles Carlton.

In 1984, U.S. Pat. No. 4,449,707 issued to Hayashi et al., for a GolfClub Head Of Carbon Fiber Reinforced Plastic, based on a Japanese PatentApplication originally filed in 1982. The Hayashi Patent disclosessurrounding a core with a fiber reinforced fabric to create a golf clubhead with a proper center of gravity.

Another disclosure is U.S. Pat. No. 4,545,580 to Tomita et al., for aWood-Type Golf Club Head, based on a Japanese Patent Applicationoriginally filed in 1983. The Tomita Patent discloses a durable golfclub head having an outer shell composed of a fiber reinforced plasticmaterial, a foam center core, and an intermediate shell formed of athermoplastic resin material.

Yet another disclosure is U.S. Pat. No. 4,630,826 to Nishigaki et al.,for Golf Club Head. The Nishigaki Patent discloses body composed of acarbon resin layer and a cast resin layer with a face insert blockcomposed of a ceramic material.

Still another disclosure is U.S. Pat. No. 4,778,185 to Kurokawa, forWood-Type Core-Shell Golf Club Heads, based on a Japanese PatentApplication originally filed in 1984. The Kurokawa Patent discloses agolf club head composed of a foam core and a shell composed of amaterial fiber reinforced plastic having long and short fibers.

Yet another disclosure is U.S. Pat. No. 4,793,616 to Fernandez, for GolfClub. The Fernandez Patent discloses a club head shell composed resinimpregnated fibers and ceramic particles within the resin to provide ahigh strength shell.

Yet another disclosure is U.S. Pat. No. 5,154,425 to Niskanen et al.,for a Composite Golf Club Head. The Niskanen Patent discloses a clubhead composed of a metal matrix composite of a ceramic matrix composite.

When a golf club head strikes a golf ball, large impacts are producedthat load the club head face and the golf ball. Most of the energy istransferred from the head to the golf ball, however, some energy is lostas a result of the collision. The golf ball is typically composed ofpolymer cover materials (such as ionomers) surrounding a rubber-likecore. These softer polymer materials having damping (loss) propertiesthat are strain and strain rate dependent which are on the order of10-100 times larger than the damping properties of a metallic clubstriking plate. Thus, during impact most of the energy is lost as aresult of the high stresses and deformations of the golf ball (0.001 to0.20 inches), as opposed to the small deformations of the metallic clubface (0.025 to 0.050 inches). A more efficient energy transfer from theclub head to the golf ball could lead to greater flight distances of thegolf ball.

The generally accepted approach has been to increase the stiffness ofthe club head face to reduce metal or club head deformations. However,this leads to greater deformations in the golf ball, and thus increasesin the energy transfer problem.

Some have recognized the problem and disclosed possible solutions. Anexample is Campau, U.S. Pat. No. 4,398,965, for a Method Of Making IronGolf Clubs With Flexible Impact Surface, which discloses a club having aflexible and resilient face plate with a slot to allow for the flexingof the face plate. The face plate of Campau is composed of a ferrousmaterial, such as stainless steel, and has a thickness in the range of0.1 inches to 0.125 inches.

Another example is Eggiman, U.S. Pat. No. 5,863,261, for a Golf ClubHead With Elastically Deforming Face And Back Plates, which disclosesthe use of a plurality of plates that act in concert to create aspring-like effect on a golf ball during impact. A fluid is disposedbetween at least two of the plates to act as a viscous coupler.

Yet another example is Jepson et al, U.S. Pat. No. 3,937,474, for a golfClub With A Polyurethane Insert. Jepson discloses that the polyurethaneinsert has a hardness between 40 and 75 shore D.

Still another example is Inamori, U.S. Pat. No. 3,975,023, for a GolfClub Head With Ceramic Face Plate, which discloses using a face platecomposed of a ceramic material having a high energy transfercoefficient, although ceramics are usually harder materials. Chen etal., U.S. Pat. No. 5,743,813 for a Golf Club Head, discloses usingmultiple layers in the face to absorb the shock of the golf ball. One ofthe materials is a non-metal material.

Lu, U.S. Pat. No. 5,499,814, for a Hollow Club Head With DeflectingInsert Face Plate, discloses a reinforcing element composed of a plasticor aluminum alloy that allows for minor deflecting of the face platewhich has a thickness ranging from 0.01 to 0.30 inches for a variety ofmaterials including stainless steel, titanium, KEVLAR®, and the like.Yet another Campau invention, U.S. Pat. No. 3,989,248, for a Golf ClubHaving Insert Capable Of Elastic Flexing, discloses a wood club composedof wood with a metal insert.

The Rules of Golf, established and interpreted by the United States GolfAssociation (“USGA”) and The Royal and Ancient Golf Club of SaintAndrews, set forth certain requirements for a golf club head. Therequirements for a golf club head are found in Rule 4 and Appendix II. Acomplete description of the Rules of Golf are available on the USGA webpage at www.usga.org. Although the Rules of Golf do not expressly statespecific parameters for a golf club face, Rule 4-1e prohibits the facefrom having the effect at impact of a spring with a golf ball. In 1998,the USGA adopted a test procedure pursuant to Rule 4-1e which measuresclub face COR. This USGA test procedure, as well as procedures like it,may be used to measure club face COR.

Although the prior art has disclosed many club head composed ofcomposite materials, the prior art has failed to provide a golf clubhead composed of a composite material that is lightweight, forgiving andhas a high coefficient of restitution.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a method for manufacturing a golf clubhead that is composed of a composite material and is forgiving whileproviding better performance than other composite golf club heads.

One aspect of the present invention is a method for producing a golfclub head composed of plies of pre-preg sheets. The method begins withcreating a face component composed of plies of pre-preg sheets. Next, acrown component composed of plies of pre-preg sheets is created and asole component composed of plies of pre-preg sheets is created using themethod. Next, the face component, the crown component and the solecomponent are assembled to create an assembled unit with an inflatablebladder within a hollow interior of the assembled unit. Next, theassembled unit is pre-compacted to create a pre-compacted unit. Finally,the pre-compacted unit is bladder molded to create a molded golf clubhead.

Having briefly described the present invention, the above and furtherobjects, features and advantages thereof will be recognized by thoseskilled in the pertinent art from the following detailed description ofthe invention when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an exploded view of a golf club head manufactured by themethod of the present invention.

FIG. 2 is a front view of a golf club head manufactured by the method ofthe present invention.

FIG. 2A is a front view of a golf club head manufactured by the methodof the present invention.

FIG. 3 is a top plan view of a golf club head manufactured by the methodof the present invention.

FIG. 4 is a heel end view of a golf club head manufactured by the methodof the present invention.

FIG. 5 is a toe end view of a golf club head manufactured by the methodof the present invention.

FIG. 6 is a bottom plan view of a golf club head manufactured by themethod of the present invention.

FIG. 7 is a cross-sectional view of the golf club head of FIG. 3 alongline 7—7.

FIG. 8 is a cross-sectional view of the golf club head of FIG. 2 alongline 8—8.

FIG. 9 is an isolated cross-section view of a face preform of thepresent invention.

FIG. 9A is an enlarged view of area A of FIG. 9.

FIG. 9B is an enlarged view of area B of FIG. 9.

FIG. 10 is an isolated cross-section view of a crown/face preform of agolf club head of the present invention.

FIG. 11 is an isolated cross-section view of a sole preform of thepresent invention.

FIG. 12 is a top plan view of a golf club head manufactured by themethod of the present invention illustrating the variation in thicknessof the walls of the golf club head.

FIG. 13 is a front plan view of a golf club head manufactured by themethod of the present invention illustrating the variation in thicknessof the walls of the golf club head.

FIG. 14 is a bottom plan view of a golf club head manufactured by themethod of the present invention illustrating the variation in thicknessof the walls of the golf club head.

FIG. 15 is a heel end view of a golf club head manufactured by themethod of the present invention illustrating the variation in thicknessof the walls of the golf club head.

FIG. 16 is a plan view of a face/crown ply having a ninety degreeorientation.

FIG. 17 is a plan view of a full face ply having a ninety degreeorientation.

FIG. 18 is a plan view of a face doubler ply having a ninety degreeorientation.

FIG. 19 is a plan view of a sole ply having a negative forty-five degreeorientation.

FIG. 20 is a flow chart of the general method of the present invention.

FIG. 21 is a flow chart of the face component creation step of themethod of the present invention.

FIG. 22 is a flow chart of the compressing molding step of the method ofthe present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed at a method of manufacturing a golfclub head that has a large volume and a minimum mass. The golf club headis forgiving and has a high coefficient of restitution thereby enablingfor less dispersion and greater distance of a golf ball hit with thegolf club of the present invention.

As shown in FIGS. 1-6, a golf club head is generally designated 20. Theclub head 20 is either a fairway wood or a driver. The drivers range inloft angle of from six degrees to fifteen degrees. The club head 20 hasa body 22 that is generally composed of a composite material such asplies of carbon pre-preg sheets. The body 22 has a crown 24, a strikingplate 26, a sole 28 with a bottom portion 28 a and a ribbon 30. Theribbon preferably has an upper ribbon wall 30 a and a lower ribbon wall30 b. The ribbon 30 generally extends from a toe end 32 to a heel end34. The ribbon 30 generally begins at one end of the striking plate 26and ends at an opposite end of the striking plate 26. A rear 36 of thebody 22 is opposite the striking plate 26 and is defined by portions ofthe ribbon 30, the crown 24 and the sole 28. Also, at the heel end 34 ofthe club head 20 is an internal tube 38 with an opening 39 for placementof a shaft therein. The internal tube 38 is placed within the hollowinterior 44 of the body 22. Within the ribbon is a weight member 40.

A sole plate 42 is disposed within a recess 29 of the bottom portion 28a of the sole 28. The sole plate 42 is preferably composed of a metalmaterial such as aluminum or titanium, and preferably has a mass of 5grams to 20 grams. A preferred mass for an aluminum sole plate 42 isapproximately 11 grams, and a preferred mass for a titanium sole plate42 is approximately 18 grams. The sole plate 42 is preferably bondedwithin the recess 29 through use of adhesives. The sole plate 42preferably has embossed graphics thereon. The sole plate 42 increasesthe durability of the club head 20 since the sole 28 often impacts theground during the striking of a golf ball.

The club head 20 also has a greater volume than a composite club head ofthe prior art while maintaining a weight that is substantially lower orequivalent to that of the prior art. The volume of the club head 20ranges from 175 cubic centimeters to 450 cubic centimeters, morepreferably ranges from 300 cubic centimeters to 400 cubic centimeters,and is most preferably 360 cubic centimeters for a driver. The mass ofthe club head 20 ranges from 165 grams to 300 grams, preferably rangesfrom 175 grams to 225 grams, and most preferably from 188 grams to 195grams. The body 22 of plies of pre-preg material has a mass ranging from80 grams to 120 grams, and most preferably 98 grams.

The volume of the golf club head 20 is increased by increasing thevertical distance of the club head 20 from the sole 28 to the crown 24,as opposed to the horizontal distance of the heel end 34 to the toe end32. This increase in volume is brought about by the dual wall structureof the ribbon 30. The upper ribbon wall 30 a is approximatelyperpendicular relative to the crown 24, while the lower ribbon wall 30 bpreferably has angle between 25 degrees to 75 degrees relative to thecrown 24. The greater volume of the club head 20 allows the club head 20to be more forgiving than prior art golf club heads while providingbetter performance. The mass of club head 20 is much lower than metalclub heads of similar volumes, and thus the large volume does not deterfrom the swing of a golfer.

The striking plate 26 has a smaller aspect ratio than striking plates ofthe prior art. The aspect ratio as used herein is defined as the width,“w”, of the striking plate divided by the height, “h”, of the strikingplate 26, as shown in FIG. 2A. In one embodiment, the width w is 90millimeters and the height h is 54 millimeters giving an aspect ratio of1.666. In conventional golf club heads, the aspect ratio is usually muchgreater than 1. For example, the original GREAT BIG BERTHA® driver hadan aspect ratio of 1.9. The aspect ratio of the present inventionpreferably ranges from 1.0 to 1.7.

As shown in FIG. 7, the internal tube 38 lies within the hollow interior44 of the club head 20. The internal tube is preferably composed of ametal material and has a mass ranging from 8 grams to 20 grams. Theinternal tube 38 is most preferably composed of stainless steel and hasa mass of approximately 14 grams. The internal tubing 38 has a bore 130to receive an insert and a shaft, not shown, therein. Such an insert isdiscussed in co-pending U.S. patent application Ser. No. 09/652,491,filed on Aug. 31, 2000, for a golf Club With Hosel Liner, which ishereby incorporated by reference in its entirety. Preferably, the clubhead 20 has a hollow interior 44 defined by the body 22, however, thelight weight of the composite body 22 allows for numerous manipulationsin placement of weight, foam, sound enhancing devices and the likewithin the hollow interior 44.

Referring specifically to FIG. 1, the club head 20 has a weight member40 disposed within the plies of pre-preg that compose the ribbon 30 ofthe club head 20. Preferably, the weight member 40 is composed of threeweight members 40 a, 40 b and 40 c. One such weight member 40 isdescribed in co-pending U.S. patent application Ser. No. 09/474,688,filed on Dec. 29, 1999, and entitled A Composite Golf Club Head With AnIntegral Weight Strip, which is hereby incorporated by reference in itsentirety. Another such weighting method is described in co-pending U.S.patent application Ser. No. 09/947,292, a for Internal Weighting For AComposite Golf Club Head, filed on an even date herewith, and herebyincorporated by reference in its entirety. The weight member 40 has amass ranging from 30 grams to 80 grams, more preferably 45 grams to 70grams, and most preferably 54 grams. The weight member 40 is preferablycomposed of a polymer material integrated with a metal material. Themetal material is preferably selected from copper, tungsten, steel,aluminum, tin, silver, gold, platinum, or the like. A preferred metal istungsten. The weight member 40 has a density greater than the compositematerial of the body 22. Preferably, the weight member 40 extends fromapproximately the heel end 34 of the striking plate 26 through the rear36 to the toe end 32 of the striking plate 26. However, the weightmember 40 may only extend along the rear 36 of the ribbon 30, the heelend 34 of the ribbon 30, the toe end 32 of the ribbon 30, or anycombination thereof. Those skilled in the pertinent art will recognizethat other weighting materials may be utilized without departing fromthe scope and spirit of the present invention.

The placement of the weighting members 40 a-c allows for the moment ofinertia of the golf club head 20 to be optimized. A more thoroughdescription of the optimization of the moments of inertia is disclosedin co-pending U.S. patent application Ser. No. 09/796,951, filed on Feb.27, 2001, entitled High Moment of Inertia Composite Golf Club, andhereby incorporated by reference in its entirety. In one preferredexample of the golf club head 20 of the present invention, the moment ofinertia about the Ixx axis through the center of gravity isapproximately 2566 grams-centimeters squared (“g-cm²”), the moment ofinertia about the Iyy axis through the center of gravity isapproximately 1895 g-cm², and the moment of inertia about the Izz axisthrough the center of gravity is approximately 3368 g-cm².

As shown in FIGS. 8, 9, 9A and 9B, a return portion 100 is a transitionarea from a perimeter 29 of the striking plate 26 rearward towards thecrown 24. The return portion 100 has a thickness ranging from 0.100 inchto 0.200 inch to control the compliance of the striking plate 26. Thereturn portion 100 has an upper section 100 a, a lower section 100 b, aheel section 100 c, not shown, and a toe section 100 d, not shown. Thereturn portion 100 also has a taper region 101, which includes an uppertapering region 101 a, a lower tapering region 101 b, a heel taperingregion 101 c, not shown, and a toe tapering region 101 d, not shown. Thetapering region 101 tapers in thickness from a greater thickness nearerthe striking plate portion 26 to a lesser thickness rearward toward thecrown 24.

The return portion 100 has a predetermined length which extends rearwardfrom the perimeter 29 of the striking plate portion 26 into the crown24. Preferably, the distance of the return portion 100, “Dr”, rangesfrom 0.25 inch to 2.0 inches, more preferably from 0.5 inch to 1.75inches, and most preferably 1.5 inches. Preferably, the distance fromthe perimeter 29 to the beginning of the tapering region 101 of thereturn portion 100 ranges from 0.25 inch to 1.5 inches, and mostpreferably 1.0 inch.

The body 22 is manufactured from a face component 125, which includesthe striking plate portion 26 and the return portion 100, a crowncomponent 124 and a sole component 128. The crown component 124 overlapsthe face component 125, as shown in FIG. 10. The sole component 128includes the ribbon portion 30 and the bottom portion 28 a. The solecomponent 128 is attached to the crown component 124 and the facecomponent 125.

FIGS. 16-19 illustrate preferred pre-preg sheets for forming thecomposite body of the golf club head 20. FIG. 16 illustrates aface/crown ply pre-preg sheet that is generally designated 55. Theface/crown ply 55 has a plurality of fibers 51 dispersed within a resinbody 53. The fibers 51 are preferably composed of a carbon material.Alternatively, the fibers 51 may be aramid fibers, glass fibers or thelike. The resin is typically an epoxy material. The relation of thefibers 51 to the striking plate 26, when the striking plate 26 is in aposition to strike a golf ball, determines the orientation of the fibers51. If the fibers 51 are parallel with the ground, or in other wordsextending across from the toe end to the heel end, then the face/crownply 55 has a zero degree orientation. If the fibers 51 are approximatelyperpendicular to the ground, as shown in FIG. 16, or in other wordsextending from the crown to the sole, then the face/crown ply 55 has aninety degrees orientation.

FIG. 17 illustrates a full face ply pre-preg sheet that is generallydesignated 57. As with the face/crown ply 55, the full face ply 57 has aplurality of fibers 51 dispersed within a resin body 53. The fibers 51extend from the sole 28 to the crown 24, and thus the full face ply 57has fibers 51 that are perpendicular to the ground when it is in aposition for striking a golf ball. Therefore, the full face ply 57 ofFIG. 17 has a ninety degrees orientation.

FIG. 18 illustrates a face doubler ply pre-preg sheet that is generallydesignated 58. As with the face/crown ply 55, the face doubler ply 58has a plurality of fibers 51 dispersed within a resin body 53. Thefibers 51 extend from the sole 28 to the crown 24, and thus the facedoubler ply 58 has fibers 51 that are perpendicular to the ground whenit is in a position for striking a golf ball. Therefore, the facedoubler ply 58 of FIG. 18 has a ninety degrees orientation.

FIG. 19 illustrates a sole ply pre-preg sheet that is generallydesignated 59. As with the face/crown ply 55, the sole ply 59 has aplurality of fibers 51 dispersed within a resin body 53. The fibers 51extend at a forty-five degree angle relative to the ground when it is ina position for striking a golf ball. Therefore, the sole ply 59 of FIG.19 has a forty-five degree orientation.

As previously stated, the preferred composite material is plies ofcarbon pre-peg sheets. Plies of pre-preg composite sheets aremanufactured by pulling strands of fiber in a parallel motion,preferably carbon, aramid or glass fiber, through a resin film andallowing the resin to partially cure or “stage”. When the resin ispartially staged, the resin holds the fibers together such that thefibers form a malleable sheet with all of the fibers in a specificorientation relative to an edge of the sheet. Preferred orientations arezero degrees, plus forty-five degrees, minus forty-five degrees andninety degrees. Exemplary carbon pre-preg fiber sheets may be obtainedfrom Newport Composites of Santa Ana, Calif., Fiberite Inc. ofGreenville, Tex., or Hexcel Inc. of Pleasonton, Calif.

The manipulation of the thickness of the various regions of the body 22allows the golf club head 20 to have superior durability, forgivenessand performance as compared to prior art composite golf club heads. Asshown in FIGS. 12-15, the thickness of the body 22 is focused on thestriking plate portion 26. In a most preferred example: the regiondesignated A of the striking plate portion 26 has a thickness ofapproximately 0.169 inch; the region designated B, at the junction ofthe crown 24 and striking plate 26 has a thickness of approximately0.188 inch; the region designated C of the bottom portion 28 a of thesole 28 has a thickness of approximately 0.221 inch; the regiondesignated D of the ribbon 30 and of the bottom portion 28 a has athickness of approximately 0.202 inch; the region designated E of thecrown 24, the bottom portion 28 a and the ribbon 30 has a thickness ofapproximately 0.033 inch; and the region designated F of the crown 24has a thickness of approximately 0.191 inch. The regions designated Z1,Z2, Z3, Z4, Z5 and Z6 are tapering zones where the thickness tapersrearward.

The golf club head 20 is preferably manufactured using a bladder moldingprocess. One such process is described in U.S. Pat. No. 6,248,025, whichis hereby incorporated by reference.

FIG. 20 illustrates the general method of the present invention. Atblock 200, the face component 125 or face cup preform is created bylaying up a plurality of plies of pre-preg sheets. The plies of pre-pregsheets create the striking plate 26 and the return portion 100 of theface component 125. A detailed example of the face component 125 is setforth below. At block 202, the crown component 124 or crown preform iscreated by laying up a plurality of plies of pre-preg sheets over theface component 125 as shown in FIG. 10. The plies of pre-preg sheetscreate the crown 24, the striking plate 26 and the return portion 100. Adetailed example of the crown component 124 is set forth below. At block204, the sole component 128 or sole preform is created by laying up aplurality of plies of pre-preg sheets with a plurality of weight members40 a-c. The plies of pre-preg sheets are folded over the plurality ofweight members 40 a-c. The plies of pre-preg sheets create the ribbon 30and the bottom portion 28 a. A detailed example of the sole component128 is set forth below.

At block 206, the face cup component 125, crown component 124 and solecomponent 128 are assembled to form an assembled unit. An inflatablebladder, preferably made from latex, silicone, or similar materials, isplaced within the interior of the assembled unit during assembly and anaccess end of the bladder is placed through the bladder port. At block208, the assembled unit is placed within a compaction device andpre-compacted to form a pre-compacted unit. At block 210, thepre-compacted unit is placed within a compression mold for bladdermolding of the pre-compacted unit into a molded unfinished golf clubhead. At block 212, the molded golf club head is finished to create thegolf club head 20.

During the bladder molding, a source of pressurized gas (not shown) isattached by a gas line to the bladder, and the bladder is inflatedwithin the hollow interior of the pre-compacted unit. The bladderengages the inside surface of the pre-compacted unit, forcing the pliesof pre-preg sheets against the inner wall of the compression mold. Themold is then heated at a predetermined temperature for a selected periodof time, i.e., a time sufficient to allow proper curing of the resinwithin the pre-preg sheets. After depressurizing, the bladder is removedthrough the bladder port 43, and the molded unfinished golf club head isremoved from the compression mold. Those skilled in the art willappreciate that, depending upon the type of resin used, curingtemperatures may range from 250° to 800° F. the requisite curing timemay range from a few minutes (for example, in the case of a “quick cure”epoxy or a thermoplastic resin) to 1.5 hours, and the pressure appliedvia the latex or silicone bladder may range from 100 to 300 psi.

FIG. 21 illustrates the face component creation process of block 200 ofFIG. 20. At block 300, a first predetermined quantity of plies ofpre-preg sheets for the face component 125 are placed within a cavityconfigured to approximate the face component 125. At block 302, thisfirst predetermined quantity of plies of pre-preg sheets for the facecomponent 125 are compressed by using a plunger or other similar deviceto create a stack of compressed plies. At block 304, a secondpredetermined quantity of plies of pre-preg sheets for the facecomponent 125 are placed within the cavity over the compressed plies. Atblock 306, this second predetermined quantity of plies of pre-pregsheets for the face component 125 are compressed by using a plunger orother similar device to create a stack of more compressed plies. Atblock 308, the process is repeated until a desired thickness of the facecomponent 125 is achieved by the process.

FIG. 22 is a flow chart of the assembly and pre-compaction steps. Atblock 400, the face-component/crown component is created by laying upthe plies of the crown component over the face component 125. At block402, the inflatable bladder is placed within the sole component 128 andextended through the bladder port 43. At block 404, the assembled unitis placed within a compaction mold, and an extension of the bladder isextended through a bore in the mold. At block 406, the compaction moldis sealed and the assembled unit is compacted to form the pre-compactionunit.

In a preferred embodiment, the face component 125 is composed offorty-eight plies of pre preg sheets: forty full face plies 57 inorientations of zero degrees, plus forty-five degrees, minus forty-fivedegrees and ninety degrees; and eight face doubler plies 58 in zerodegrees and ninety degrees orientations. The crown component 124, whichis applied over the face component 125, is composed of seven face/crownplies 55 in orientations of zero degrees, plus forty-five degrees, minusforty-five degrees and ninety degrees. The sole component 128 iscomposed of seven sole plies 59 in orientations of zero degrees, plusforty-five degrees, minus forty-five degrees and ninety degrees. Thesecond and third pairs of sole plies 59 are folded over the plurality ofweight members 40 a-c. In this preferred embodiment, the outer plies area twill pattern for aesthetic purposes and some durability support.

From the foregoing it is believed that those skilled in the pertinentart will recognize the meritorious advancement of this invention andwill readily understand that while the present invention has beendescribed in association with a preferred embodiment thereof, and otherembodiments illustrated in the accompanying drawings, numerous changes,modifications and substitutions of equivalents may be made thereinwithout departing from the spirit and scope of this invention which isintended to be unlimited by the foregoing except as may appear in thefollowing appended claims. Therefore, the embodiments of the inventionin which an exclusive property or privilege is claimed are defined inthe following appended claims.

We claim as our invention:
 1. A method for producing a golf club headcomposed of plies of pre-preg sheets, the method comprising: creating aface component composed of plies of pre-preg sheets, the face componenthaving a striking plate portion and a return portion; creating a crowncomponent composed of plies of pre-preg sheets; creating a solecomponent composed of plies of pre-preg sheets, the sole componenthaving a ribbon and a bottom portion; assembling the face component, thecrown component and the sole component to create an assembled unit withan inflatable bladder within a hollow interior of the assembled unit;pre-compacting the assembled unit to create a pre-compacted unit; andbladder molding the pre-compacted unit to create a molded golf clubhead.
 2. The method according to claim 1 wherein the face component iscomposed of 20 to 70 plies of pre-preg sheets.
 3. The method accordingto claim 1 wherein the sole component is composed of 4 to 20 plies ofpre-preg sheets and a plurality of weighting members.
 4. The methodaccording to claim 1 wherein the crown component is composed of 4 to 20plies of pre-preg sheets.
 5. The method according to claim 1 wherein theclub head has a volume ranging from 175 cubic centimeters to 600 cubiccentimeters.